EP3479712B1 - Thermal liner for protective garments - Google Patents

Thermal liner for protective garments Download PDF

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Publication number
EP3479712B1
EP3479712B1 EP18201602.2A EP18201602A EP3479712B1 EP 3479712 B1 EP3479712 B1 EP 3479712B1 EP 18201602 A EP18201602 A EP 18201602A EP 3479712 B1 EP3479712 B1 EP 3479712B1
Authority
EP
European Patent Office
Prior art keywords
nonwoven
gsm
aramid
thermal liner
fiber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18201602.2A
Other languages
German (de)
French (fr)
Other versions
EP3479712A1 (en
Inventor
Brian P. Shiels
Kimberly M. Henry
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
PBI Performance Products Inc
Original Assignee
PBI Performance Products Inc
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Filing date
Publication date
Application filed by PBI Performance Products Inc filed Critical PBI Performance Products Inc
Priority to PL18201602T priority Critical patent/PL3479712T3/en
Publication of EP3479712A1 publication Critical patent/EP3479712A1/en
Application granted granted Critical
Publication of EP3479712B1 publication Critical patent/EP3479712B1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00Materials specially adapted for outerwear
    • A41D31/04Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06Thermally protective, e.g. insulating
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D27/00Details of garments or of their making
    • A41D27/02Linings
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00Materials specially adapted for outerwear
    • A41D31/04Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06Thermally protective, e.g. insulating
    • A41D31/065Thermally protective, e.g. insulating using layered materials
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00Materials specially adapted for outerwear
    • A41D31/04Materials specially adapted for outerwear characterised by special function or use
    • A41D31/08Heat resistant; Fire retardant
    • A41D31/085Heat resistant; Fire retardant using layered materials
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00Materials specially adapted for outerwear
    • A41D31/04Materials specially adapted for outerwear characterised by special function or use
    • A41D31/12Hygroscopic; Water retaining
    • A41D31/125Moisture handling or wicking function through layered materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326Condensation or reaction polymers
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326Condensation or reaction polymers
    • D04H1/4334Polyamides
    • D04H1/4342Aromatic polyamides
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D2400/00Functions or special features of garments
    • A41D2400/10Heat retention or warming
    • AHUMAN NECESSITIES
    • A62LIFE-SAVING; FIRE-FIGHTING
    • A62BDEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
    • A62B17/00Protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes
    • A62B17/003Fire-resistant or fire-fighters' clothes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/20All layers being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0246Acrylic resin fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04Cellulosic plastic fibres, e.g. rayon
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06Vegetal fibres
    • B32B2262/062Cellulose fibres, e.g. cotton
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/08Animal fibres, e.g. hair, wool, silk
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/304Insulating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/306Resistant to heat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/306Resistant to heat
    • B32B2307/3065Flame resistant or retardant, fire resistant or retardant
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/726Permeability to liquids, absorption
    • B32B2307/7265Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00Protective equipment
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Definitions

  • the instant invention is directed to a thermal liner for use in, for example, protective garments.
  • Protective garments are now well known for many and varied uses, such as suits for industrial workers, firefighters, wildlands firefighters, race car drivers, airplane pilots, and military personnel. Garments include not only complete, full body suits, but also individual garments such as trousers, jackets, gloves, boots, hats, head coverings, masks, etc. Generally, protective garments are designed to shield a wearer from a variety of environmental hazards. Firefighter garments are representative of such protective garments.
  • Firefighter garments are designed primarily to prevent the firefighter from sustaining serious burns.
  • a second significant threat to firefighters is heat stress. More firefighter deaths occur in the United States each year due to heat stress related conditions than due to burns. Heat stress related conditions include elevated body core temperature leading to heat prostration, increased blood pressure, heatstroke, and sometimes heart attack. As this second threat has become recognized, the fire service community has attempted to modify and improve turnout gear to minimize its contribution to heat stress.
  • turnout gear includes a coat and overalls.
  • Turnout gear typically comprises three layers: an outer shell, a moisture barrier, and a thermal barrier.
  • the outer shell layer is usually a woven fabric made from flame resistant fibers and is considered the firefighter's first line of defense. Not only should it resist flame, but it needs to be tough and durable so as not to be torn, unduly abraded, or snagged during normal firefighting activities.
  • the moisture barrier layer while also flame resistant, is provided to prevent water from penetrating and saturating the turnout gear. Excess moisture from the environment would laden the firefighter with extra weight and therefore increase their load. Such an increase in load is likely to increase the possibility of heat stress.
  • the thermal barrier liner is also flame resistant and offers the bulk of the thermal protection afforded by the ensemble.
  • a traditional thermal barrier liner includes an insulation layer of flame resistant fibers quilted to a lightweight woven face cloth also made of flame resistant fibers.
  • a material commonly used as a component in the thermal barrier, and often regarded as an industry standard, is known as E89® from DuPont of Richmond, VA.
  • E89 is a spunlaced nonwoven material consisting of NOMEX® (meta-aramid) staple or KEVLAR® (para-aramid) staple or a combination of both, Technical Guide for NOMEX® Brand Fiber, H-52720 Revised July 2001 by DuPont, Richmond, VA, page 3 .
  • Nonwovens used in thermal layers have been suggested and they are disclosed in US Patents 4937136 , 5136723 , 5236769 , 6430754 , 6743498 , 7676855 , and US Publication 2002/0069453 .
  • US4937136 teaches an inner thermal liner made with a nonwoven fabric of a blend of wool and a synthetic fiber capable of high temperature performance.
  • the synthetic fibers include, among others, NOMEX, KEVLAR, and polybenzimidazole (PBI).
  • US5136723 teaches an inner thermal barrier made with a mesh (apertured) fabric of NOMEX or KEVLAR having a basis weight of about 2 osy (ounces per square yard) or 67.8 gsm (grams per square meter). This mesh fabric is believed to be E89.
  • US5236769 teaches textile layer of a nonwoven made with 100% aramids, mixtures of 30-50% wool and heat stable fiber, such as PBI. This nonwoven has a basis weight of 200 gsm (5.9 osy) at a thickness of 4 mm.
  • US2007/0137012 is directed to a thermally protective fabric including a composition of inherently flame resistant fibers, and interstices having insulating pockets of air.
  • US6407019 is directed to, among other things, an insulating lining made of at least a two ply nonwoven where each nonwoven ply has a basis weight of 80 gsm.
  • WO 01/66193 discloses, among other things, a thermal liner made of a nonwoven of aramid of PBI materials.
  • US6430754 teaches a second layer of insulating material of 50.8 gsm (1.5 osy) E89 or a spunlaced nonwoven of a blend of aramid and PBI fibers. US6430754 also teaches an alternate embodiment where the thermal barrier has a first layer of 78.0 gsm (2.3 osy) E89 (spunlaced nonwoven) and a second layer of 50.8 gsm (1.5 osy) E89 (spunlaced nonwoven).
  • US6743498 teaches an insulating barrier of a perforated nonwoven having a basis weight in the range of 100-200 gsm and made from a variety of thermostable fiber including, among others, aramids and PBI.
  • US767855 teaches an insulation layer of a nonwoven made of, among other things, aramids or melamines (but no PBI), the nonwoven maybe hydroentangled, and the basis weight of the nonwoven may be in the range of 25.4-271.2 gsm (0.75-8 osy). In the exemplary examples, the nonwoven is 84.8 gsm (2.5 osy) and made of 50% BASOFIL® melamine/25% meta-aramid/25% para-aramid.
  • US Publication 2002/0069453 teaches the insulation layer comprising a blend of inherently hydrophobic fibers and non-hydrophobic, flame resistant fibers.
  • the hydrophobic fibers include polytetrafluoroethylene (PTFE) fibers.
  • the non-hydrophobic fibers include aramid fibers, PBI fibers, polybenzoxazole (PBO) fibers, melamine fibers, and blends thereof.
  • the present invention provides a thermal liner for protective apparel comprising: a nonwoven having 15-30 wt % of a polybenzimidazole fiber, the remaining balance being an aramid fiber, the nonwoven excluding wool and cellulosic fibers, and having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm).
  • the protective apparel is a firefighter's turnout gear.
  • the nonwoven for use in the thermal liner for example for use in a protective apparel, includes 15-30 wt % of the polybenzimidazole fiber as a first inherently heat resistant fiber, and a balance of aramid fiber as a second heat resistant fiber.
  • the nonwoven excludes wool and has a thickness less than 3 mm and a basis weight of less than 100 gsm (2.9 osy).
  • the thermal liner for protective apparel includes a nonwoven including an inherently flame resistant fiber and fibers being inherently resistant to moisture absorption.
  • the inherently flame resistant fiber is different from said inherently resistant to moisture absorption fiber.
  • the nonwoven has an equivalent or better thermal protective performance (TPP) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both.
  • the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%.
  • said nonwoven is a spunlaced and an apertured nonwoven.
  • the thermal liner further comprises a facing fabric affixed to said nonwoven.
  • the thermal liner further comprises multiple nonwovens.
  • the present inventions provides a protective garment comprising a nonwoven thermal liner according to any of the examples described above.
  • protective garment 10 is the jacket of a firefigther's turnout suit. It is understood, however, that the invention is not limited to firefighter's turnout gear. The invention may be used in other types of protective gear, as will be apparent to those of ordinary skill.
  • Such other types of protective suits include, but are not limited to, suits for industrial workers (including, for example, arc flash apparel), wildlands firefighters, race car drivers, airplane pilots, military personnel, and the like.
  • the protective garment 10 may have a multi-layer construction that includes an outer shell 20, a moisture barrier 40, and a thermal liner 60.
  • the outer shell 20 is typically constructed of a flame and abrasion resistant material that comprises flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof.
  • the outer shell 20 may be treated with a water-resistant finish (for example, a perfluorohydrocarbon) to prevent or reduce water absorption from the outside environment.
  • the weight of the outer shell material may be within the range of about 203.4-271.2 gsm, i.e. 6-8 ounces per square yard (osy).
  • the moisture barrier 40 may be constructed of a non-woven or woven flame resistant fabric 42 comprising flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof.
  • the moisture barrier 40 may be laminated with a water-impermeable layer 44 of material such as, for instance, a layer of polytetrafluoroethylene (PTFE) or polyurethane (PU). When such an impermeable layer 44 is provided, it usually is provided on the moisture barrier 40, so as to face the thermal liner 60.
  • the weight of the moisture barrier material is typically within the range about 135.6-203.4 gsm (4-6 osy).
  • the thermal liner 60 may, optionally, include both an insulation layer 62 and a facecloth layer 64, which may be quilted together. In alternative embodiments, however, the insulation layer 62 alone may be used.
  • the insulation layer 62 is discussed in greater detail below.
  • the facecloth layer 64 may be constructed of woven material comprising flame resistant fibers made of, for example, aramid (meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, flame resistant (FR) cellulosics, modacrylic, carbon, or the like, and blends thereof.
  • the facecloth layer 64 may be, optionally, finished with a hydrophilic finish that draws perspiration off of the firefighter's body, if desired.
  • the weight of the facecloth layer material is normally in the range of about 33.9-203.4 gsm (1-6 osy).
  • the insulation layer 62 comprises a nonwoven material that comprises a plurality of flame resistant fibers, discussed in greater detail below.
  • the insulation layer 62 may comprise a single layer of nonwoven, or two layers of nonwoven, or multiple layers of nonwoven. In one embodiment, the insulation layer has two layers of nonwoven material, and each of these layers may have a different basis weight.
  • the nonwoven material may be a weight range of about 25.4-271.2 gsm (0.75-8 osy). In one embodiment, the nonwoven material may be in a weight range of about 39.9-101.7 gsm (1.0-3.0 osy). In another embodiment, the nonwoven material may be in a weight range of 40.7-84.8 gsm (1.2-2.5 osy).
  • the nonwoven material may be in a weight range of 40.7-67.8 gsm (1.2-2.0 osy).
  • the insulation layer may comprise two nonwoven layer, one layer having a basis weight of about 47.5 gsm (1.4 osy) and the other layer having a basis weight of about 61.0 gsm (1.8 osy).
  • the nonwoven material may have a thickness of less than 2 mm. In another embodiment, the nonwoven material may have a thickness of less than 1 mm. The nonwoven material, in all embodiments, should have a minimum thickness of 0.25 mm. In still another embodiment, the nonwoven material may have a thickness in the range of about 0.75-1.25 mm.
  • the nonwoven material may be made by any nonwoven process. Such processes include, but are not limited to, wet laid, air laid, carding, felting, needlepunching, and hydroentangling (spunlaced). In one embodiment, the nonwoven may be spunlaced.
  • the nonwoven material may be flat (i.e., without apertures), apertured (see US5136723 ), dimpled (see US7676855 ), or a combination of any of the foregoing.
  • the nonwoven may comprise a plurality of flame resistant fibers.
  • the nonwoven may exclude any wool and/or cellulosic fibers and/or natural fibers (i.e., any non-synthetic or non-man-made fibers).
  • the nonwoven may be characterized has having an equivalent or better thermal protective performance (TPP per NFPA 1971 (2007)) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both, for example - E89.
  • the flame resistant fibers may also be characterized as non-water absorbing fibers.
  • Non-water absorbing fiber does not refer to the moisture regain of the fiber.
  • Moisture regain refers to percentage of atmospheric moisture in a textile material brought into equilibrium with a standard atmosphere after partial drying, calculated as a percentage of the moisture-free weight.
  • non-water absorbing fiber refers to the fibers ability, when placed in contact with liquid water, to swell, absorb, and retain that water.
  • the water absorbency of fibers may be measured according to ASTM D2402 (2012). The maximum water retention that may be tolerated is less than 15%.
  • the first inherently heat resistant fiber of the nonwoven material is selected from the group consisting of polybenzimidazoles.
  • the second heat resistant fiber of the nonwoven material is selected from the group of aramids (meta- and/or para-aramids).
  • the full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner.
  • the outer shell was PBI MATRIX® available from Safety Components, Inc of Greenville, SC.
  • the moisture barrier was CROSSTECH 2C available from W.L. Gore & Associates of Elkton, MD.
  • the thermal barrier was unquilted and made with a NOMEX face cloth and the insulation layers set forth in TABLE 2. The first two listed materials are existing industry standard constructions and the remaining are examples of the instant invention.
  • TABLE 3A-D there is shown several full composite comparisons of the instant invention to various industry standard full composites.
  • the full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner.
  • the outer shell was varied as indicated.
  • the moisture barrier was varied as indicated.
  • the thermal barrier was quilted and varied as indicated.
  • TABLE 3A Outer Shell PBI MATRIX - Safety Components, Inc, Greenville, SC. Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD.
  • Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Glide Araflo 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 38.9 65.4 / 1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide E89 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 63.4 / 1.87 67% m-aramid 78.0 gsm, 2.3osy flat Caldura SL2 2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 64.4 / 1.90 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D 2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 41.8 71.2 / 2.10 67% m-aramid 78.0 gsm, 2.3osy
  • Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Caldura SL2 1 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 36.4 65.5 /1.93 67% m-aramid 78.0 gsm, 2.3osy flat Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.7 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 . Flat: spunlaced nonwoven without apertures. 1 Available from TenCate, Union City, GA.
  • Thermal Liner Fiber Blend Insulation Layers TPP 3 TPP gsm / osy Caldura SL2 1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 38.2 66.8 / 1.97 67% m-aramid 78.0 gsm, 2.3osy flat Quantum 3D 1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 41.3 67.8 / 2.00 67% m-aramid 78.0 gsm, 2.3osy dimpled Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 40.3 68.8 / 2.03 w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured Apertured: spunlaced nonwoven with apertures, see for example US513723 .

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  • Chemical & Material Sciences (AREA)
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  • General Health & Medical Sciences (AREA)
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Description

    Field of the Invention
  • The instant invention is directed to a thermal liner for use in, for example, protective garments.
  • Background of the Invention
  • Protective garments are now well known for many and varied uses, such as suits for industrial workers, firefighters, wildlands firefighters, race car drivers, airplane pilots, and military personnel. Garments include not only complete, full body suits, but also individual garments such as trousers, jackets, gloves, boots, hats, head coverings, masks, etc. Generally, protective garments are designed to shield a wearer from a variety of environmental hazards. Firefighter garments are representative of such protective garments.
  • Firefighter garments, generally known as turnout gear, are designed primarily to prevent the firefighter from sustaining serious burns. A second significant threat to firefighters is heat stress. More firefighter deaths occur in the United States each year due to heat stress related conditions than due to burns. Heat stress related conditions include elevated body core temperature leading to heat prostration, increased blood pressure, heatstroke, and sometimes heart attack. As this second threat has become recognized, the fire service community has attempted to modify and improve turnout gear to minimize its contribution to heat stress.
  • Generally, turnout gear includes a coat and overalls. Turnout gear typically comprises three layers: an outer shell, a moisture barrier, and a thermal barrier. The outer shell layer is usually a woven fabric made from flame resistant fibers and is considered the firefighter's first line of defense. Not only should it resist flame, but it needs to be tough and durable so as not to be torn, unduly abraded, or snagged during normal firefighting activities.
  • The moisture barrier layer, while also flame resistant, is provided to prevent water from penetrating and saturating the turnout gear. Excess moisture from the environment would laden the firefighter with extra weight and therefore increase their load. Such an increase in load is likely to increase the possibility of heat stress.
  • The thermal barrier liner is also flame resistant and offers the bulk of the thermal protection afforded by the ensemble. A traditional thermal barrier liner includes an insulation layer of flame resistant fibers quilted to a lightweight woven face cloth also made of flame resistant fibers. A material commonly used as a component in the thermal barrier, and often regarded as an industry standard, is known as E89® from DuPont of Richmond, VA. E89 is a spunlaced nonwoven material consisting of NOMEX® (meta-aramid) staple or KEVLAR® (para-aramid) staple or a combination of both, Technical Guide for NOMEX® Brand Fiber, H-52720 Revised July 2001 by DuPont, Richmond, VA, page 3.
  • While E89 is an excellent material, there is a need to find better materials, i.e., materials with the same or better thermal protection and lower weights.
  • Nonwovens used in thermal layers have been suggested and they are disclosed in US Patents 4937136 , 5136723 , 5236769 , 6430754 , 6743498 , 7676855 , and US Publication 2002/0069453 .
  • US4937136 teaches an inner thermal liner made with a nonwoven fabric of a blend of wool and a synthetic fiber capable of high temperature performance. The synthetic fibers include, among others, NOMEX, KEVLAR, and polybenzimidazole (PBI).
  • US5136723 teaches an inner thermal barrier made with a mesh (apertured) fabric of NOMEX or KEVLAR having a basis weight of about 2 osy (ounces per square yard) or 67.8 gsm (grams per square meter). This mesh fabric is believed to be E89.
  • US5236769 teaches textile layer of a nonwoven made with 100% aramids, mixtures of 30-50% wool and heat stable fiber, such as PBI. This nonwoven has a basis weight of 200 gsm (5.9 osy) at a thickness of 4 mm.
  • US2007/0137012 is directed to a thermally protective fabric including a composition of inherently flame resistant fibers, and interstices having insulating pockets of air.
  • US6407019 is directed to, among other things, an insulating lining made of at least a two ply nonwoven where each nonwoven ply has a basis weight of 80 gsm.
  • WO 01/66193 discloses, among other things, a thermal liner made of a nonwoven of aramid of PBI materials.
  • US6430754 teaches a second layer of insulating material of 50.8 gsm (1.5 osy) E89 or a spunlaced nonwoven of a blend of aramid and PBI fibers. US6430754 also teaches an alternate embodiment where the thermal barrier has a first layer of 78.0 gsm (2.3 osy) E89 (spunlaced nonwoven) and a second layer of 50.8 gsm (1.5 osy) E89 (spunlaced nonwoven).
  • US6743498 teaches an insulating barrier of a perforated nonwoven having a basis weight in the range of 100-200 gsm and made from a variety of thermostable fiber including, among others, aramids and PBI.
  • US767855 teaches an insulation layer of a nonwoven made of, among other things, aramids or melamines (but no PBI), the nonwoven maybe hydroentangled, and the basis weight of the nonwoven may be in the range of 25.4-271.2 gsm (0.75-8 osy). In the exemplary examples, the nonwoven is 84.8 gsm (2.5 osy) and made of 50% BASOFIL® melamine/25% meta-aramid/25% para-aramid.
  • US Publication 2002/0069453 teaches the insulation layer comprising a blend of inherently hydrophobic fibers and non-hydrophobic, flame resistant fibers. The hydrophobic fibers include polytetrafluoroethylene (PTFE) fibers. The non-hydrophobic fibers include aramid fibers, PBI fibers, polybenzoxazole (PBO) fibers, melamine fibers, and blends thereof.
  • Summary of the Invention
  • The present invention provides a thermal liner for protective apparel comprising: a nonwoven having 15-30 wt % of a polybenzimidazole fiber, the remaining balance being an aramid fiber, the nonwoven excluding wool and cellulosic fibers, and having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm). Advantageously the protective apparel is a firefighter's turnout gear.
  • In one embodiment the nonwoven for use in the thermal liner, for example for use ina protective apparel, includes 15-30 wt % of the polybenzimidazole fiber as a first inherently heat resistant fiber, and a balance of aramid fiber as a second heat resistant fiber. The nonwoven excludes wool and has a thickness less than 3 mm and a basis weight of less than 100 gsm (2.9 osy). In another embodiment, the thermal liner for protective apparel includes a nonwoven including an inherently flame resistant fiber and fibers being inherently resistant to moisture absorption. The inherently flame resistant fiber is different from said inherently resistant to moisture absorption fiber. The nonwoven has an equivalent or better thermal protective performance (TPP) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both.
  • In one example of the thermal liner the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%.
  • In one example of the thermal liner said nonwoven is a spunlaced and an apertured nonwoven.
  • In still another example, the thermal liner further comprises a facing fabric affixed to said nonwoven.
  • In yet another example, the thermal liner further comprises multiple nonwovens.
  • According to another aspect the present inventions provides a protective garment comprising a nonwoven thermal liner according to any of the examples described above.
  • Description of the Drawings
  • For the purpose of illustrating the invention, there is represented in the figures data from various embodiments of the invention; it being understood, however, that this invention is not limited to the data shown and that this data is not necessarily been optimized, but instead only indicates the possibilities for the inventive materials.
    • Figure 1 is an illustration of a protective garment, parts broken away.
    • Figure 2 is an exploded view of the layers of the protective garment shown in Figure 1.
    Description of the Invention
  • Referring to the Figures, wherein like numerals refer to like elements, there is shown in Figure 1, a protective garment 10. Specifically, protective garment 10 is the jacket of a firefigther's turnout suit. It is understood, however, that the invention is not limited to firefighter's turnout gear. The invention may be used in other types of protective gear, as will be apparent to those of ordinary skill. Such other types of protective suits include, but are not limited to, suits for industrial workers (including, for example, arc flash apparel), wildlands firefighters, race car drivers, airplane pilots, military personnel, and the like.
  • As indicated in Figures 1 and 2, the protective garment 10 may have a multi-layer construction that includes an outer shell 20, a moisture barrier 40, and a thermal liner 60. The outer shell 20 is typically constructed of a flame and abrasion resistant material that comprises flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. The outer shell 20 may be treated with a water-resistant finish (for example, a perfluorohydrocarbon) to prevent or reduce water absorption from the outside environment. The weight of the outer shell material may be within the range of about 203.4-271.2 gsm, i.e. 6-8 ounces per square yard (osy).
  • The moisture barrier 40 may be constructed of a non-woven or woven flame resistant fabric 42 comprising flame resistant fibers made of, for example, aramid (meta- and/or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, or the like, and blends thereof. The moisture barrier 40 may be laminated with a water-impermeable layer 44 of material such as, for instance, a layer of polytetrafluoroethylene (PTFE) or polyurethane (PU). When such an impermeable layer 44 is provided, it usually is provided on the moisture barrier 40, so as to face the thermal liner 60. The weight of the moisture barrier material is typically within the range about 135.6-203.4 gsm (4-6 osy).
  • The thermal liner 60 may, optionally, include both an insulation layer 62 and a facecloth layer 64, which may be quilted together. In alternative embodiments, however, the insulation layer 62 alone may be used. The insulation layer 62 is discussed in greater detail below. When it is used, the facecloth layer 64 may be constructed of woven material comprising flame resistant fibers made of, for example, aramid (meta-aramid or para-aramid), polybenzimidazole (PBI), polybenzoxazole (PBO), melamine, flame resistant (FR) cellulosics, modacrylic, carbon, or the like, and blends thereof. The facecloth layer 64 may be, optionally, finished with a hydrophilic finish that draws perspiration off of the firefighter's body, if desired. The weight of the facecloth layer material is normally in the range of about 33.9-203.4 gsm (1-6 osy).
  • The insulation layer 62 comprises a nonwoven material that comprises a plurality of flame resistant fibers, discussed in greater detail below. The insulation layer 62 may comprise a single layer of nonwoven, or two layers of nonwoven, or multiple layers of nonwoven. In one embodiment, the insulation layer has two layers of nonwoven material, and each of these layers may have a different basis weight. The nonwoven material may be a weight range of about 25.4-271.2 gsm (0.75-8 osy). In one embodiment, the nonwoven material may be in a weight range of about 39.9-101.7 gsm (1.0-3.0 osy). In another embodiment, the nonwoven material may be in a weight range of 40.7-84.8 gsm (1.2-2.5 osy). In yet another embodiment, the nonwoven material may be in a weight range of 40.7-67.8 gsm (1.2-2.0 osy). In still another embodiment, the insulation layer may comprise two nonwoven layer, one layer having a basis weight of about 47.5 gsm (1.4 osy) and the other layer having a basis weight of about 61.0 gsm (1.8 osy). In one embodiment, the nonwoven material may have a thickness of less than 2 mm. In another embodiment, the nonwoven material may have a thickness of less than 1 mm. The nonwoven material, in all embodiments, should have a minimum thickness of 0.25 mm. In still another embodiment, the nonwoven material may have a thickness in the range of about 0.75-1.25 mm. The nonwoven material may be made by any nonwoven process. Such processes include, but are not limited to, wet laid, air laid, carding, felting, needlepunching, and hydroentangling (spunlaced). In one embodiment, the nonwoven may be spunlaced. The nonwoven material may be flat (i.e., without apertures), apertured (see US5136723 ), dimpled (see US7676855 ), or a combination of any of the foregoing.
  • The nonwoven may comprise a plurality of flame resistant fibers. The nonwoven may exclude any wool and/or cellulosic fibers and/or natural fibers (i.e., any non-synthetic or non-man-made fibers). The nonwoven may be characterized has having an equivalent or better thermal protective performance (TPP per NFPA 1971 (2007)) and a lower basis weight than an industry standard nonwoven consisting of a nonwoven of para-aramids or meta-aramids or a blend of both, for example - E89.
  • In one embodiment, the flame resistant fibers may also be characterized as non-water absorbing fibers. Non-water absorbing fiber does not refer to the moisture regain of the fiber. Moisture regain, as used herein, refers to percentage of atmospheric moisture in a textile material brought into equilibrium with a standard atmosphere after partial drying, calculated as a percentage of the moisture-free weight. Instead, non-water absorbing fiber refers to the fibers ability, when placed in contact with liquid water, to swell, absorb, and retain that water. The water absorbency of fibers may be measured according to ASTM D2402 (2012). The maximum water retention that may be tolerated is less than 15%.
  • The first inherently heat resistant fiber of the nonwoven material is selected from the group consisting of polybenzimidazoles.
  • The second heat resistant fiber of the nonwoven material is selected from the group of aramids (meta- and/or para-aramids).
  • Examples
  • The following examples further illustrate the invention; it being understood, however, that this invention is not limited to the precise formulations set forth.
  • In Table 1, there are shown several representative embodiments of the instant invention compared to the certain industry standard materials. These embodiments illustrate a range of thickness and basis weights that may be useful in the manufacture of turnout gear. Fiber blends A-B represent the inventive embodiments and fiber blend C represents an industry standard material. TABLE 1
    Fiber Blend Structure Basis Weight Thickness (mm) (mm/gsm) · 100
    (gsm) [osy]
    A Apertured 56.9 [1.68] 0.89 1.56
    A Apertured 66.5 [1.96] 0.97 1.46
    A Apertured 84.6 [2.50] 1.10 1.30
    B1 Apertured 48.1 [1.42] 0.74 1.54
    B1 Apertured 62.0 [1.83] 0.93 1.50
    B Apertured 77.7 [2.29] 1.07 1.38
    B Apertured 85.0 [2.50] 1.19 1.40
    C2 Flat 50.0 [1.47] 0.70 1.40
    C3 Flat 80.0 [2.36] 0.87 1.09
    C Dimpled 80.0 [2.36] 1.22 1.53
    A: 47 wt% m-aramid/33% p-aramid/20% PBI
    B: 80 wt% m-aramid/20% PBI
    C: 67 wt% m-aramid/33% p-aramid
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    Dimples: spunlaced nonwoven without apertures but having dimples, see for example US7676855 . Also referred to in the industry as '3D.'
    Conversion: (gsm/33.9)=osy.
    1Exemplary embodiment.
    2Industry standard - 50.1.gsm (5osy) spunlace.
    3Industry standard - 78.0 gsm (2.3osy) spunlace.
  • In TABLE 2, there are shown several full composite comparisons of the instant invention industry standards. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was PBI MATRIX® available from Safety Components, Inc of Greenville, SC. The moisture barrier was CROSSTECH 2C available from W.L. Gore & Associates of Elkton, MD. The thermal barrier was unquilted and made with a NOMEX face cloth and the insulation layers set forth in TABLE 2. The first two listed materials are existing industry standard constructions and the remaining are examples of the instant invention. TABLE 2
    Fiber Blend Insulation Layers Full Composite basis Weight TPP4 TPP gsm/osy
    gsm (osy)
    33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 677.7 (19.99) 35.5 60.3/1.78
    67% m-aramid1 78.0 gsm, 2.3osy flat
    33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 661.0 (19.55) 36.4 63.0/1.86
    67% m-aramid2 78.0 gsm, 2.3osy dimpled
    20 wt% PBI/ 47.5 gsm, 1.4osy apertured 640.4 (18.89) 36.2 65.0/1.92
    80% m-aramid3 61.0 gsm, 1.8osy apertured
    47wt% m-aramid/ 57.6 gsm, 1.7osy apertured 642.4 (18.95) 34.7 62.0/1.83
    33% p-aramid/20% PBI 57.6 gsm, 1.7osy apertured
    47wt% m-aramid/ 67.8 gsm, 2.0osy apertured 653.2 (19.27) 36.7 64.4/1.90
    33% p-aramid/20% PBI 57.6 gsm, 1.7osy apertured
    20 wt% PBI/ 47.5 gsm, 1.4osy apertured 657.3 (19.39) 37.2 65.0/1.92
    80% m-aramid 78.0 gsm, 2.3osy apertured
    20 wt% PBI/ 61.0 gsm, 1.8osy apertured 658.0 (19.41) 36.6 64.0/1.89
    80% m-aramid 61.0 gsm, 1.8osy apertured
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    Dimples: spunlaced nonwoven without apertures but having dimples, see for example US7676855 .
    1Industry standard
    2Industry standard
    3Exemplary embodiment
    4TPP - Thermal Protection Performance per NFPA1971 (2007).
  • In TABLE 3A-D, there is shown several full composite comparisons of the instant invention to various industry standard full composites. The full composite refers turnout gear with an outer shell, moisture barrier, and a thermal liner. The outer shell was varied as indicated. The moisture barrier was varied as indicated. The thermal barrier was quilted and varied as indicated. TABLE 3A
    Outer Shell: PBI MATRIX - Safety Components, Inc, Greenville, SC.
    Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD.
    Thermal Liner Fiber Blend Insulation Layers TPP3 TPP
    gsm / osy
    Glide Araflo1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 38.9 65.4 / 1.93
    67% m-aramid 78.0 gsm, 2.3osy flat
    Glide E891 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 63.4 / 1.87
    67% m-aramid 78.0 gsm, 2.3osy flat
    Caldura SL22 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 37.6 64.4 / 1.90
    67% m-aramid 78.0 gsm, 2.3osy flat
    Quantum 3D2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 41.8 71.2 / 2.10
    67% m-aramid 78.0 gsm, 2.3osy dimpled
    Glide 1 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.3 64.4 / 1.90
    w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    Dimples: spunlaced nonwoven without apertures but having dimples, see for example US7676855 .
    1Available from Safety Components, Inc, Greenville, SC.
    2Available from TenCate, Union City, GA.
    3TPP - Thermal Protection Performance per NFPA1971 (2007).
    TABLE 3B
    Outer Shell: PBI MAX - Safety Components, Inc, Greenville, SC.
    Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD
    Thermal Liner Fiber Blend Insulation Layers TPP3 TPP
    gsm / osy
    Glide Araflo1 33 wt%p-aramid/ 50.9 gsm, 1.5osy apertured 39.2 71.2 / 2.10
    67% m-aramid 78.0 gsm, 2.3osy flat
    Glide E891 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 39.7 70.2 / 2.07
    67% m-aramid 78.0 gsm, 2.3osy flat
    Quantum 3D2 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 42.2 73.2 / 2.16
    67% m-aramid 78.0 gsm, 2.3osy dimpled
    Glide 1 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 43.4 74.6 / 2.20
    w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    Dimples: spunlaced nonwoven without apertures but having dimples, see for example US7676855 .
    1Available from Safety Components, Inc, Greenville, SC.
    2Available from TenCate, Union City, GA.
    3TPP - Thermal Protection Performance per NFPA1971 (2007).
    TABLE 3C
    Outer Shell: GEMINI - TenCate, Union City, GA.
    Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD.
    Thermal Liner Fiber Blend Insulation Layers TPP3 TPP
    gsm / osy
    Caldura SL21 33 wt%p-aramid/ 50.9 gsm, 1.5osy flat 36.4 65.5 /1.93
    67% m-aramid 78.0 gsm, 2.3osy flat
    Glide
    2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 39.7 68.8 / 2.03
    w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    1Available from TenCate, Union City, GA.
    2Available from Safety Components, Inc, Greenville, SC.
    3TPP - Thermal Protection Performance per NFPA1971 (2007).
    TABLE 3D
    Outer Shell: GEMINI XT - TenCate, Union City, GA.
    Moisture barrier - CROSSTECH Black, W.L. Gore & Associates, Elkton, MD.
    Thermal Liner Fiber Blend Insulation Layers TPP3 TPP
    gsm / osy
    Caldura SL21 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 38.2 66.8 / 1.97
    67% m-aramid 78.0 gsm, 2.3osy flat
    Quantum 3D1 33 wt%p-aramid/ 50.0 gsm, 1.5osy flat 41.3 67.8 / 2.00
    67% m-aramid 78.0 gsm, 2.3osy dimpled
    Glide 2 20 wt% PBI/ 47.5 gsm, 1.4osy apertured 40.3 68.8 / 2.03
    w/invention 80% m-aramid 61.0 gsm, 1.8osy apertured
    Apertured: spunlaced nonwoven with apertures, see for example US513723 .
    Flat: spunlaced nonwoven without apertures.
    Dimples: spunlaced nonwoven without apertures but having dimples, see for example US7676855 .
    1Available from TenCate, Union City, GA.
    2Available from Safety Components, Inc, Greenville, SC.
    3TPP - Thermal Protection Performance per NFPA1971 (2007).

Claims (8)

  1. A thermal liner (60) for protective apparel (10) comprising: a nonwoven (62) having
    15-30 wt % of a polybenzimidazole fiber,
    the remaining balance being an aramid fiber,
    the nonwoven excluding wool and cellulosic fibers, and
    having a thickness less than 3 mm and a basis weight of less than 2.9 osy (100 gsm).
  2. The thermal liner (60) of claim 1, wherein the polybenzimidazole fiber is a first inherently heat resistant fiber and the aramid fiber is a second heat resistant fiber.
  3. The thermal liner (60) of claim 2, wherein the first inherently heat resistant fiber and the second heat resistant fiber have a water retention of less than 15%, as measured by ASTM D2402 (2012).
  4. The thermal liner (60) of any of claims 1 to 3, wherein the protective apparel (10) being a firefighter's turnout gear.
  5. The thermal liner (60) of any of claims 1 to 4, wherein said nonwoven (62) being a spunlaced and an apertured nonwoven.
  6. The thermal liner (60) of any of the preceding claims, further comprising a facing fabric (64) affixed to said nonwoven (62).
  7. The thermal liner (60) of any of the preceding claims, further comprising multiple nonwovens (62).
  8. A protective garment (10) comprising a thermal liner (60) according to any of the preceding claims 1 to 7.
EP18201602.2A 2012-09-25 2013-09-03 Thermal liner for protective garments Active EP3479712B1 (en)

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US13/626,179 US9409378B2 (en) 2012-09-25 2012-09-25 Thermal liner for protective garments
EP13840310.0A EP2900097B1 (en) 2012-09-25 2013-09-03 Thermal liner for protective garments
PCT/US2013/057773 WO2014051936A1 (en) 2012-09-25 2013-09-03 Thermal liner for protective garments

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EP (2) EP2900097B1 (en)
ES (2) ES2860455T3 (en)
PL (2) PL2900097T3 (en)
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US20140087129A1 (en) 2014-03-27
US20160227858A1 (en) 2016-08-11
ES2705528T3 (en) 2019-03-25
PL2900097T3 (en) 2019-03-29
EP2900097A4 (en) 2016-06-01
PL3479712T3 (en) 2021-06-28
US20220053859A1 (en) 2022-02-24
EP3479712A1 (en) 2019-05-08
EP2900097A1 (en) 2015-08-05
ES2860455T3 (en) 2021-10-05
EP2900097B1 (en) 2018-10-24
US9409378B2 (en) 2016-08-09
WO2014051936A1 (en) 2014-04-03

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